Alignment Module for Irregular Edges

Abstract

The present invention relates to an alignment module (11) for a converting machine (1). The alignment module includes an alignment device (30) having an upper pressing member (22), a lower conveyor (24), and a guide (26). The guide further includes a downwardly sloping entrance end (32) configured to guide a lateral portion of a blank under the guide while bringing lateral guide surfaces (40) into contact with inner segment ends (S1, S2) of the blank, the inner segment ends being positioned closer to the longitudinal center axis of the blank than the lateral portion of the blank positioned under the guide.

Description

[Technical Field]

[0001] The present invention relates to a converting machine for producing paper and corrugated containers, such as folding boxes. In particular, the present invention relates to an alignment module configured to laterally align blanks having irregular lateral edges. [Background technology]

[0002] Converting machines, such as folder-gluers, are used in the manufacture of paperboard and corrugated boxes. These machines are configured to receive cut-to-shaped blanks, which are then folded and glued to form folding boxes and other similar packaging boxes. The blanks include cut lines that define the overall shape of the blank and crease lines that define the locations of the folds.

[0003] To ensure that the folds occur at the locations defined by the crease lines, the folding-gluing machine includes a registration module located upstream of the folding module. The registration module is configured to laterally register the blank. An example of a registration module is described in U.S. Patent No. 7,398,872.

[0004] The registration module of U.S. Patent No. 7,398,872 includes an upper press member and a lower conveyor configured to receive and transport blanks in the gap therebetween. The blanks are transported with one lateral edge biased against a lateral guide extending in the blank transport direction. In this manner, the blanks are laterally registered within the converting machine.

[0005] Depending on the shape of the blank, the alignment module can be configured to adjust the alignment relative to the left or right side of the blank. Generally, straight or uniform lateral edges are more advantageous than irregular lateral edges for alignment with the guide. However, for some blanks, both the left and right lateral edges are irregular. These types of blanks are designed to form crushlock boxes, wallet-type packaging boxes, hand-elected boxes, etc. These boxes may also include adhesive stripes.

[0006] As a result, these types of blanks are difficult to align in the conveying direction and there is a risk of causing the blank to rotate during conveyance within the alignment module. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] U.S. Patent No. 7,398,872 Summary of the Invention [Problem to be solved by the invention]

[0008] In view of the prior art, it is an object of the present invention to improve the alignment of blanks with irregular lateral edges. [Means for solving the problem]

[0009] This object is solved by an alignment module as claimed in claim 1.

[0010] According to a first aspect of the present invention, there is provided an alignment module for a converting machine, the alignment module being configured to correct a lateral position of a blank transported through the converting machine in a conveying direction. The blank has a first lateral periphery and a second lateral periphery, the first and second lateral periphery being disposed on opposite sides of a central longitudinal axis of the blank and extending in the conveying direction. The alignment module includes at least one alignment device having an upper pressure member, a lower conveyor, and a guide, the upper pressure member and the lower conveyor being configured to receive and transport the blank in a gap therebetween, the guide being an elongated rod-like body with a lateral guide surface and extending in the conveying direction.

[0011] The guide further includes a downwardly sloping entry end configured to guide the lateral portions of the blank beneath the guide while contacting the lateral guide surface with an inner segment edge of the blank, the inner segment edge being positioned closer to the central longitudinal axis of the blank than the lateral portions of the blank positioned beneath the guide. The downwardly sloping entry end has a wedge shape.

[0012] The first and second lateral peripheral edges may be irregular and comprise a plurality of segment edges, each extending in the conveying direction and positioned at different lateral locations from the central longitudinal axis of the blank. "Irregular edges" means edges that are not straight.

[0013] Each lateral perimeter edge includes one distal segment edge and at least one inner segment edge, the inner segment edge being located closer to the central longitudinal axis of the blank than the distal segment edge.

[0014] The guide is disposed laterally of the upper pressure member and the conveyor belt.

[0015] The present invention is based on the recognition that an irregular lateral edge comprises a plurality of different segment edges located at different lateral positions. The position and length of some of the inner segment edges make them more favorable for alignment than the laterally most distally located segment edges, i.e., the distal lateral edges. The lateral direction is defined as the direction perpendicular to the blank conveyance direction. By providing a guide with a downwardly inclined entry portion beneath which the blank edge is pressed, the inner lateral segment ends can be accessed by the alignment surface of the guide.

[0016] According to one embodiment, the lower conveyor is positioned such that lateral portions of the blank are not supported by the lower conveyor.

[0017] In this way, the edge is unsupported and guided downwardly under the alignment guide with the aid of gravity.

[0018] In one embodiment, the alignment guide comprises a groove configured to retain a guide edge of the blank, the guide edge being an inside edge of the blank.

[0019] In one embodiment, the registration module includes an entrance portion where the upper pressure member is positioned a predetermined distance from the lower conveyor, and the downwardly sloping entrance end of the guide is located at the entrance portion.

[0020] The alignment guide is laterally displaceable.

[0021] In one embodiment, the upper alignment module further comprises a slider, and the connecting axis of the slider and the connecting axis of the guide rail coincide.

[0022] According to a second aspect of the present invention, there is provided a converter including an alignment module according to the first aspect of the present invention, the converter further including a folding module and a blank rotation module configured to rotate a blank by 90°. The converter includes a second alignment module disposed between the blank rotation module and the folding module.

[0023] The blank rotation module and the second alignment module can be separate modules mounted on two separate chassis. Alternatively, the blank rotation module and the second alignment module can be a composite module having a single chassis.

[0024] Here, the present invention will be described with reference to the accompanying drawings, in which like reference numerals denote like features.

Brief Description of the Drawings

[0025] [Figure 1] It is a schematic view of a converter of the configuration of a folding-gluing machine. [Figure 2a] It is a schematic perspective view of a folding box. [Figure 2b] It is a plan view of a blank. [Figure 3] It is a schematic perspective view of an alignment module according to an embodiment of the present invention. [Figure 4] It is a schematic cross-sectional view of the alignment module and the feeder module of FIG. 3. [Figure 5a] It is a detailed plan view of the entrance portion of the alignment module according to an embodiment of the present invention. [Figure 5b] It is a cross-sectional view of the entrance portion of FIG. 5a. [Figure 6] It is a cross-sectional view of the entrance portion of FIG. 5b having a blank 2. [Figure 7] It is a top view of the feeder module and the alignment module according to an embodiment of the present invention.

Modes for Carrying Out the Invention

[0026] Referring to the drawings, and in particular to Figures 1, 2a and 2b, the folding and gluing machine 1 is configured to receive cut-formed blanks 2, such as those shown in Figure 2b, and thereafter fold and glue the blanks 2 to form folding boxes 2' or other folded and glued packaging boxes 2'.

[0027] 1, the folding-gluing machine 1 of the present invention may comprise a series of various workstations in the form of modules. From the inlet to the outlet and in the conveying direction T, the modules may include a feeder module 10, an alignment module 11, a folding and pre-breaking module 12, a gluing module 14, and a folding module 16. The folding-gluing machine 1 may further comprise a main user interface 15 and a quality control system 18.

[0028] The alignment module 11 is arranged downstream of the feeder module 10 in the conveying direction T and is configured to laterally align the blank 2 in a predetermined lateral position, which is defined by the position of the longitudinal fold line 4 and the positions of the folding and auxiliary tools in the converting machine 1. The alignment module 11 is therefore configured to align the blank 2 in a direction perpendicular to the conveying direction T.

[0029] Between the alignment module 11 and the folding and pre-breaking module 12, auxiliary modules in the form of a glue strip module 13 and a blank rotation module 17 can be arranged. The glue strip module is configured to apply a glue strip (i.e., an adhesive line) and a protective cover, so that the glue strip can be used to reseal the box after the first use. Such glue strip modules are offered by Enpro, e.g., in the "SPA 3.0 - Silicone Paper Applicator" series. The blank rotation module 17 is configured to rotate the blank 2 by 90 degrees before it enters the folding module 16. An example of a blank rotation module is described in EP 3038954.

[0030] Preferably, the second alignment module 9 is located between the blank rotation module 17 and the folding module 16. The blank rotation module 17 and the second alignment module 9 can be separate modules mounted on two separate chassis, or the blank rotation module 17 and the second alignment module 9 can be a combined module having a single chassis.

[0031] After the gluing module 14 and the folding module 16, a delivery module and conditioning section 21 may be provided for counting and separating the stream of shingles of folding boxes 2' into separate batches.

[0032] The converting machine 1 further comprises a conveying system 19 comprising conveyors such as endless belts and rollers configured to transport the blanks 2 in a conveying direction T. The converting machine 1 also comprises a central control circuit 20 configured to control the operation of the converting machine 1.

[0033] To enable folding, the blank 2 is provided with crease lines 4. A first set of crease lines 4a extends in the conveying direction T of the blank 2 in the alignment module 11. Also, the first set of crease lines 4a extends in the conveying direction T of the blank 2 in the feeder module 10.

[0034] The second fold lines 4b are arranged perpendicular to the first fold lines 4a. If a blank rotation module 17 is used, the second fold lines 4b extend in the conveying direction T of the blank in the folding module 16.

[0035] The blank 2 has a longitudinal length La in the conveying direction T in the alignment module 11. Similarly, if the blank rotation module 17 is used, the blank 2 has a longitudinal length Lb in the conveying direction T in the rotation module 16. For blanks 2 with irregular leading and trailing edges, the longitudinal lengths La, Lb are the maximum lengths of the blank 2 in the conveying direction T.

[0036] In the alignment module 11, the blank 2 comprises a first lateral peripheral edge 6a and a second lateral peripheral edge 6b. The first and second lateral peripheral edges 6a, 6b may be irregular. The lateral peripheral edges 6a, 6b allow for the formation of flaps and folding surfaces.

[0037] The first lateral periphery 6a includes a plurality of segment edges S1 positioned at different lateral positions relative to the central longitudinal axis C of the blank 2. The central longitudinal axis C coincides with the conveying direction in the alignment module 11. Preferably, the central longitudinal axis C is located at the center of the blank 2. Similarly, the second lateral periphery 6b includes a plurality of segment edges S2 positioned at different lateral positions relative to the central longitudinal axis C of the blank 2. Depending on the type of packaging box 2' and the shape of the blank 2, the number of segment edges S1, S2 may vary. The lateral position is defined as the distance in the lateral direction L, which is defined as the direction perpendicular to the conveying direction T of the blank 2 in the alignment module. Therefore, the lateral direction L can also be defined as the direction perpendicular to the conveying direction T of the blank 2 in the feeder module 10.

[0038] Each lateral perimeter edge 6a, 6b includes one distal segment edge D1, D2 and at least one inner segment edge S1, S2 positioned closer to the central longitudinal axis C of the blank 2 than the distal segment edge D1, D2. The distal segment edges D1, D2 are located at the lateral ends of the blank 2 in the alignment module 11.

[0039] 3, the alignment module 11 preferably includes a first alignment device 30a and a second alignment device 30b. The first alignment device 30a is configured to abut the left side of the blank 2, and the second alignment device 30b is configured to abut the right side of the blank 2.

[0040] As can be best seen in FIG. 5 a, the alignment devices 30 a , 30 b include an upper pressure member 22 having a plurality of pressure rollers 23 arranged in a row, an alignment conveyor 24 , and a guide 26 .

[0041] The alignment module 11 is configured to receive the blank 2 in the gap between an upper pressure member 22 and an alignment conveyor 24. The upper pressure member 22 and the alignment conveyor 24 are arranged at an angle to the conveying direction T so as to orient the lateral edges 6 a, 6 b of the blank 2 towards the guide 26. The guide 26 is arranged with its longitudinal extension coinciding with the conveying direction T.

[0042] The alignment conveyor 24 includes an endless conveyor belt 25 and is configured to contact the blank 2 and drive the blank 2 forward in the conveying direction T. The pressure roller 23 may be an idle roller.

[0043] The first and second alignment devices 30a, 30b are not used simultaneously, instead they provide the option of selecting which lateral edge 6a, 6b of the blank 2 is aligned with the guide 26.

[0044] When one of the alignment devices 30a, 30b is activated, the other alignment device is deactivated. In the inactivated alignment device 30a, 30b, the pressure roller 23 can move upward and away from the blank 2, so that the pressure roller 23 of the inactivated alignment device 30a, 30b does not come into contact with the blank 2.

[0045] As shown in Figure 5a, the alignment module 11 can include an entrance section I. The entrance section I provides a distance through which the blanks 2 are not guided. This can be achieved by positioning at least some of the pressing rollers 23 so that they are positioned at a predetermined distance from the alignment conveyor 24. In this way, the pressing members 22 do not grip the blanks 2, and the trajectory of the blanks 2 in the entrance section I is not altered by the alignment device 30.

[0046] The length of the inlet section I can be configured such that the blank 2 is moved laterally only if the entire longitudinal length La of the blank 2 is within the alignment module 11. This allows the alignment module 11 to receive the entire longitudinal length La of the blank 2 before moving the blank 2 laterally. This also allows the blank 2 to exit the feeder module 10 before changing its trajectory.

[0047] The alignment side is selected based on the shape of the lateral peripheral edges 6 a, 6 b of the blank 2. The choice between right-side alignment and left-side alignment can be selected manually by an operator by inspecting the first and second lateral peripheral edges 6 a, 6 b. Alternatively, the control unit 50 can perform calculations to determine which lateral peripheral edge 6 a, 6 b is best suited for alignment.

[0048] Ideally, long, straight distal segment edges D1, D2 are selected as suitable alignment edges. However, some blanks 2, such as those shown in FIG. 2b, have irregular lateral peripheries 6a, 6b, where the distal segment edges D1, D2 are relatively short in the conveying direction T. With regard to irregular lateral peripheries 6a, 6b, the alignment device 11 of the present invention also enables alignment with the inner segment edges S1, S2. This is advantageous when the inner segment edges S1, S2 are straight (in the conveying direction T) and have a significant length in the conveying direction T in the alignment module 11. Preferably, the significant length is about 50% of the longitudinal length La.

[0049] As best seen in Figures 5a and 5b, guide 26 comprises an inlet end 32, an outlet end 34, and a longitudinal guide portion 36. Inlet end 32 is inclined downward in conveying direction T. Guide 26 has an upper surface 37 and a lower surface 39. Upper surface 37 and lower surface 39 preferably have extensions coinciding with horizontal direction H, with the upper surface being disposed vertically above the lower surface in vertical direction V. In inlet section I, upper surface 37 of guide 26 extends further upstream in conveying direction T than lower side 39 of guide 26. Thus, with its downwardly inclined inlet end 32, guide 26 is configured to guide transverse portion E0 of the blank below guide 26.

[0050] The inclination angle α can be between 20° and 40°, preferably about 30°, relative to the longitudinal extension of the guide 26. The entrance end 32 therefore has a wedge shape and is configured to guide the distal segment ends D1, D2 and the lateral portion E0 of the blank 2 under the guide 26, thereby allowing the front leading edge of the blank 2 to be partially guided under the guide 26. The entrance end 32 of the guide 26 can be located in an entrance section in which the blank 2 is not guided laterally.

[0051] As shown in FIG. 5b, the longitudinal guide portion 36 has alignment surfaces 40 configured to abut the inner segment edges S1, S2 of the blank 2. The alignment surfaces 40 of the guide 26 can be flat. Alternatively, as shown in FIG. 5b, the alignment surfaces 40 can include grooves 41 configured to receive selected inner alignment edges S1, S2 of the blank 2.

[0052] In the entrance section I, the alignment surface 40 of the guide 26 can be positioned a predetermined lateral distance from selected inner alignment edges S1, S2. In this way, the guide 26 does not contact a guide edge on the blank 2 until the lateral portion E0 of the blank 2 is positioned under the guide 26.

[0053] 7, the registration module 11 is positioned downstream of the feeder module 10. The feeder module 10 includes a loading surface 42 configured to receive a stack of blanks 2. The loading surface 42 includes a plurality of drive belts 44 configured to contact and drive the bottom blank 2 of the stack forward in the conveying direction T.

[0054] The lower conveyor 24 is positioned laterally such that the lateral portion E0 of the blank 2 extends further laterally and is unsupported. The distal-most drive belt 44, which is positioned at selected guide edges S1, S2 of the blank 2, is positioned further outward in the lateral direction in the alignment module 11 than the lower conveyor 24.

[0055] This creates a lateral gap d2 in the conveying path. However, a central portion of the blank 2 is supported by at least one conveyor 24. Thus, gap d2 provides a distance over which distal segment edges D1, D2 of the blank 2 are unsupported. Gap d2 allows distal segment edges D1, D2 to drop vertically under the influence of gravity as the blank exits feeder module 10. This helps sloped entrance edge 32 guide distal segment ends D1, D2 under guide 26.

[0056] The upper alignment module may further include a slider 28. The slider 28 is configured to contact the blank laterally of the guide 26 to prevent vertical movement of the blank. [Explanation of symbols]

[0057] 1 Converter 11 Alignment Module 22 Upper pressing member 24 Lower conveyor 26 Guide 30 Alignment Device 32 Inlet end 40 Lateral guide surface S1, S2 inner segment ends

Claims

1. a registration module (11) for a converting machine (1), the registration module being configured to correct a lateral position of a blank (2) being conveyed in a conveying direction (T) through the converting machine, the blank having a first lateral edge (6a) and a second lateral peripheral edge (6b), the first and second lateral peripheral edges being arranged on opposite sides of a central longitudinal axis (C) of the blank and extending in the conveying direction; The alignment module comprises at least one alignment device (30a, 30b) having an upper pressing member (22), a lower conveyor (24), and a guide (26); The upper pressing member and the lower conveyor are configured to receive and convey the blanks in a gap therebetween, and the guide is an elongated rod-like body having a lateral guide surface (40) and extending in the conveying direction; the guide further comprises a downwardly sloping entrance end (32) configured to guide a lateral portion (E0) of the blank under the guide while bringing the lateral guide surface (40) into contact with an inner segment end (S1, S2) of the blank, the inner segment end being positioned closer to the central longitudinal axis of the blank than the lateral portion of the blank positioned under the guide.

2. 2. The registration module of claim 1, wherein the lower conveyor (24) is positioned such that the lateral portion (E0) of the blank is not supported by the lower conveyor.

3. 3. The alignment module of claim 1 or 2, wherein the alignment guide comprises a groove (41), the groove configured to retain the inner segment edges (S1, S2) of the blank.

4. 4. The alignment module according to claim 1, wherein the alignment module comprises an entrance portion (I) in which the upper pressing member is positioned at a predetermined distance from the lower conveyor, and the downwardly inclined entrance end of the guide is located in the entrance portion (I).

5. The alignment module of claim 1 , wherein the alignment guide is laterally displaceable.

6. The alignment module of claim 1 , wherein the upper alignment module further comprises a slider, and a connection axis (AC) of the slider and the connection axis of the guide rail are coincident.

7. 7. A converting machine (1) comprising an alignment module (11) according to any one of claims 1 to 6, further comprising a folding module (16) and a blank rotation module (17) configured to rotate the blank by 90°, wherein a second alignment module (9) is arranged between the blank rotation module and the folding module.

Images